Electrolytic process for producing halogen gases and the apparatus therefor



Jan. 7, 1964 w. JUDA 3,117,066

ELECTROLYTIC PRocEss FOR PRODUCING HALOGEN GAsEs AND THE APPARATUS THEREFOR Filed Nov. l, 1960 ELECTROLYTE HALOGEN 2O Amma United States Patent O 3,117,966 LECTRQLYTIC PRCESS FR PRDUCENG HALQGEN GASES AND THE APPARATUS THEREFQR Walter duda, Lexington, Mass., assigner to ionics incorporated, Cambridge, Mass., a corporation of Massachusetts Filed Nov. 1, i960, Ser. No. 66,498 6 Claims. (Cl. Zita- 128) This invention relates to the electrochemical conversion of selected halogen acids to halogens, and more particularly to electrolytic processes and apparatus for converting selected halogen acids to halogens through the use of electrical energy produced, at least in part, by the reaction at an electrode of an oxidant gas supplied thereto.

Fuel cells, known in the art, can be characterized as electrochemical cells in which a substantial portion of the chemical energy of an oxidation-reduction reaction is converted directly -to useful electrical energy. In an exemplary fuel cell, a fuel, such as hydrogen gas, and an oxidant, such as oxygen gas, are diffused respectively through a pair of porous, catalyzed electrodes separated by an electrolyte. The reaction of the fuel and oxidant creates electrical energy which is readily available at the electrodes.

The electrolysis of selected halogen acids, such as hydrogen chloride and hydrogen zliuoride, to produce the respective halogen, is a well-known process. Typically, certain chlorination processes often produce large quantities of hydrogen chloride as a by-product, and the regeneration of the chlorine from the acid has recognized commercial significance. -in regenerating the halogen by electrolysis, the acid gas is adsorbed in water or -in an aqueous solution of acid at low concentration, thereby producing a relatively concentrated acid solution. The latter is fed to electrolytic cells wherein it is decomposed into hydrogen and chlorine by the application of electrical energy to the cell. Because the cell requires complete separation of the gaseous products due to the inherent explosiveness of a mixture of the gases, the cell is often bulky and expensive. The hydrogen, too, is often an undesired product which nevertheless must be processed for recovering acid condensate therefrom, and this necessitates still further equipment.

The use of electrolytic cells for effecting electrochemical conversions with `electrical energy derived, in part, from the reaction in the cell has been disclosed in my copending U.S. patent applications, Ser. No. 842,892, filed September 28, 1i959; Ser. No. 3,418, filed January 19, 1960i;

er. No. 7,046, led February 5, 1960. In these disclosures, the anode process, i.e., the ionization of a fuel supplied to the anode, was employed to produce by direct conversion, part of the energy consumed in the over-all process. in my co-pending U.S. patent application, Ser. No. 8,269, filed February l2, 1960, now abandoned, part of the DC. energy used in the chemical conversion of certain organic compounds was produced by la process at a porous cathode supplied with oxidant gas. Consequently, the present invention contemplates the employment of catalytic, porous electrodes supplied with oxidant gas, eg., oxygen, air, ozone, etc., to directly produce electrical energy at cathodes in the chemical conversion of HC1 to chlorine and HF to fluorine with the attendant reduction of outside power necessary for performing the process.

A principal object of the present invention is therefore to provide a process involving the employment of oxidant fuel cathodes in chemical conversion cells for producing selected halogens. Other objects of the present invention are to provide an improved electrolytic means for producing chlorine from hydrogen chloride without the evolution of gaseous hydrogen; to provide an improved 3,1i7,05ii Patented Jan. 7, 1964 ICC electrolytic means for producing lfiuorine from hydrogen liuoride without the evolution of gaseous hydrogen; to provide means of the type described which is an improvement over the prior -art in compactness, cost of construction, and cost of external'electrical power required in its operation; and to provide an electrochemical apparatus for the conversion of selected halogen acids to the corresponding halogen, which apparatus employs catalytic, porous cathode means, and means for supplying oxidant gas to the cathode means during operation of the apparatus.

Gther objects -o-f the invention will in part beobvious and will in part appear hereinafter.

The invention `accordingly comprises the apparatus possessing the construction, combination of elements, and an arrangement ofipar-ts which are exemplified lin the following detailed disclosure, and the scope of the application of which will be indicated in the claims.

lFor a fuller understanding of the nature and objects of the invention, reference should -be had to the following detailed description taken in connection with the accompanying drawing in which:

FIGURE l is a schematic, sectional, side elevational view of an electrochemical conversion cell embodying the principles of the present invention, and

FIGURE 2 is a schematic, sectional, side elevational view of an alternative cathode-barrier assembly for use -in the embodiment of FIGURE l.

Referring now to FIGURE l, there is `shown an exemplary cell for the electrochemical conversion of a selected halogen acid to its halogen. The cell, in the form shown, comprises a substantially hollow cylindrical container or cell body Zd which is preferably formed of a material which is not attacked, or attacked only superoally, by the electrolyte or the halogen. Por instance, such metals as platinum, silver, Mo-nel metal, nickel, magnesium, and copper may be employed as well as such other materials as graphite, polytetraiiuoroethylene, and the like. One end of the cell body 28 -is capped with circular lid 2C.r which is firmly retained in a position of closure by appropriate fastening means, such as bolts 24, which connect an annular flange 26` about cell body 20 with peripheral'portions of the lid. In order to providea proper seat for the lid and to prevent the escape of corrosive materials from the interior of the cell body, one embodiment includes a gasket 2S between the lid and the cell body. The-gasket may be formed of such materials as.polytetraiiuoroethylene and polychlo-rtriuorethylene where the cell is to beemployed for fluorine production, and `of the aforesaid materials as well as polyvinylchloride and polychlorbutadiene where the cell is to he employed `for chlorine production. The lid may include a plurality of openings therein into which ducting means such as tubes 30 and 32 are inserted. The former provides inlet means through which the electrolyte is intended to be introduced into the interior of the cell; the latter provides egress means `through which the halogen is intended to be withdrawn from the cell.

Lid 22 also includes, -approximately centrally thereof, aperture 34 through which extends anode support means which, in the form shown, comprises rod 36. Rod 36, being made of an electrically conductive material, also comprises means for carrying an electrical current to the anode. In the event that cell body 20l is also formed of an electrically conductive material, such as one of the metals heretofore mentioned, the rod is preferably insulated from the cell body by gasket 3-8. The latter is dimensioned -to occupy the space between the rod and the internal margin of aperture 34 so as to provide a liquid and gas-proof seal. Gasket 3,8 is preferably Iformed of the same materials as gasket 28, the choice of materials, of course, being determined by the nature of the halogen involved.

Suspended `from the extremity of rod 36 which ex- 4 tends internally of cell body 2.9 and electrically coupled thereto is anode 40. `In the preferred embodiment, the anode comprises a hollow, cylindrical or tubular element having a closed end which is firmly bonded to rod 36. The anode may, for example, be formed of graphite or carbon although other anode materials, such as nickel, platinum, copper, iron, platinized titanium, platinized tantalum, silicon carbide, magnesium, aluminum, other noble metals, or titanium and tantalum coated with other noble metals, or the like may be used.

The apparatus of the invention includes cathode 42 which, in the form shown in FIGURE l, is shaped as an elongated, cylindrical element, disposed coaxially with anode 4t) within the hollow interior of the latter. The cathode is dimensioned so that its external diameter is substantially smaller than the internal diameter of anode 4t), and is, therefore, predeterminedly spaced from the internal lWalls of the latter. In the form shown, the .cathode includes an interior space or hollow axis 44 into which an oxidant gas, such as air, oxygen, ozone, etc. is intended to be introduced. Therefore, ducting means, such as tube 46, is coupled mechanically and electrically with hollow axis 4S thereby providing a pneumatic passageway or gas inlet port to the cathode. Tube 46 preferably is formed of an electrically conductive material thereby constituting means for carrying an electrical current to the cathode. Cathode 42 is a microporous, catalyzed body formed of suitable materials such as microporous carbon having distributed therein catalytic metal, such as silver or gold, or other noble metals, including platinum, and mixtures thereof, or as a1 sintered, microporous mat or grid of silver or gold a one.

In order to avoid significant contamination by oxidant gas of the halogen evolved at the anode, and to avoid contamination of halogen acid by products evolved at the cathode, one form of the invention includes means for separating the electrodes from one another as by an ion-permeable barrier 48. In the embodiment shown in FIGURE l, barrier 48 is shaped as a closed, tubular element positioned substantially coaxially `with and between both the cathode and the anode, being predetermiuedly spaced from both of the electrodes. In one form of the invention, barrier 4S is a selectively ionpermeable membrane. Examples of such ion-permeable membranes and methods for making the same can be for instance, in U.S. Patent No. 2,636,851, issued April 28, 1953, to W. Juda et al., and in U.S. Patent No. 2,730,768, issued January 17, 1956, to l. Clarke. In cells wherein a membrane of the type described would too rapidly be rendered inoperative by chemical attack, barrier 4S comprises yet another structure, serving a similar purpose, for instance, a porous ldiaphragm of polyvinyl chloride, Monel metal, electronmagnesium alloy, or the like. In the form shown in FIGURE 2, wherein like numerals denote like parts, the barrier takes the form of a selectively ion-permeable membrane positioned between the cathode and anode and in direct contact with cathode 42. This alternative form permits the eicient utilization of oxidant gases under relatively low pressures. The juxtaposed position of the membrane with the cathode permits the membrane to operate as an electrolyte per se, therefore obviating the need for providing any additional electrical connection between the barrier and the cathode.

In the embodiment shown in FIGURE l, cell kbody 20, at the end thereof opposite to the end capped by lid 22, is provided 4with a substantially circular opening 50 disposed approximately centrally thereof. Means such as ring 52 for supporting barrier 4S are provided, ring 52 being shaped to t snugly, as by threading, into opening 50. Ring 52 includes a central aperture therein which is dimensioned to fit snugly about cathode 42, thereby providing a seal which separates the cath- Ode from the cell body, retains the cathode in its coaxial position relative to the anode, and supports barrier 43 so that working electrolyte within the hollow interior of the cell body cannot contact the cathode. Ring 52 includes therein ducting means such as inlet port 54 and outlet port 56 through which respectively an ionic solution can be introduced and withdrawn from the interspace between the cathode and the barrier. Such an ionic solution provides the necessary initial electrical continuity between the cathode and the barrier.

Referring now to the embodiment illustrated in FIG- URE 2, cell body Ztl, at the end thereof (shown in fragment) opposite to the end capped by lid 22, is provided with a substantially circular opening t). Means such as ring 6b for supporting barrier 5S are provided, ring 69 being shaped similarly to ring 52 to iit snugly into opening Sil. Ring dit includes a central aperture therein which is dimensioned to t snugly about cathode 42; the ring thus provides a seal which separates the cathode from the cell body and retains the cathode in its position relative to the anode. In this embodiment, barrier 43 comprises an ion-permselective membrane in intimate physical and electronic `contact with the external surface or" cathode 42 thereby separating the latter completely from the interior of the cell.

In operation, where it is desired to employ the cell of FIGURE l for instance for the manufacture of iluorine from hydrogen fluoride, a continuous supply of anhydrous hydrofluoric acid is fed into the interior of cell body 2o through inlet port 30 under slight pressure, or HF fed into the cell is maintained under continuous pressure. As its dissociation is very poor, pure HF is virtually non-conductive electrically. Hence, in order to increase considerably its conductivity, the hydroliuoric acid includes a small amount of HF-soluble iiuorides such as potassium or ammonium lluoride, which dissociate to provide ions which conduct an electrical Icurrent. The operating temperature of the cell is determined by the requirement that the electrolyte remains liquid; the relative concentration of HF with respect to the fluorine salt determines, to a large extent, the optimum temperature at which the cell is to be operated. An oxidizing gas, such as oxygen, is fed through inlet port 46 into the internal cathode space 44. And, an ionic, aqueous solution, for instance, water containing a small amount of sulfuric acid (which will not decompose readily while carrying an electrical current) is introduced through inlet port 54 into the interspace between cathode 42 and membrane 48. A direct electrical current from an external power source, such as a battery (not shown) is impressed upon the cell with the proper polarity through rod 36 and tube 46.

The oxygen is presumably adsorbed on the surface of the cathode and catalyzed to produce anions at the electrode-solution interface, thereby withdrawing current producing electrons from the cathode. Simultaneously, the passage of direct current through the cell libcrates uorine as a gas at the anode, and the hydrogen ions are flushed through barrier 43 (which in this embodiment is preferably a macroporous diaphragm) together with some HF and into the ionic, aqueous solution The hydrogen ions combine with the anions produced at the cathode to form water. Elemental iluorine thus formed at the anode is withdrawn from the cell through outlet port 32 While the water product together with some HF, both now segregated from the halogen acid by the diaphragm, are withdrawn along with the Solution in a .continuous stream from outlet port S6. The continuous flow of HF through the diaphragm and into the interspace between the diaphragm and cathode provides the necessary electrical continuity thereafter. The HF in theieluent from port 32 can be recovered and reintroduced into cell body 2t) according to known techniques.

The operation of the embodiment shown in FIGURE 2 is quite similar. For instance, where it is desired to employ this embodiment for the manufacture of chlorine from hydrogen chloride, a highly concentrated hydrochloric acid solution is fed into the interior of the cell body through inlet port 30. As with the operation previously described, an oxidizing gas is fed into the internal cathode space 44 and a direct electrical current is impressed upon the cell through rod 36 and tube 46. Because of the proximity of membrane 48 to the cathode in this embodiment, there is no problem of maintaining electrical continuity therebetween. As in the operation of the embodiment of FIGURE l, the oxygen is formed at the cathode into anions and simultaneously, the passage of current through the cell liberates chlorine as a gas at the anode While hydrogen ions move through the membrane to combine with the anions thereby forming water at the cathode-membrane interface. Elemental chlorine is Withdrawn `from the cell through outlet port 32, the continuous stream of oxidant gas into the cathode evaporating the Water product therefrom and removing it as an effluent vapor.

In the standard electrolysis of a halogen acid, the halfcell reactions can be expressed as follows where X represents the halogen:

where X is chlorine, the anode reaction potential in an acid medium requires 1.36 volts, the normal cathode reaction being the reference voltage. The total reaction, 2X--}-2H+ H2|X2 then requires 1.36 volts where X is chlorine, and 2.85 volts where X is fluorine, over-voltage being neglected.

On the other hand, in the process of the present invention, while the anode reaction remains the same, the cathode reaction may be expressed as, 1/:O2|2H+- H2O. This cathode reaction produces theoretically 1.23 volts; hence, again neglecting overvoltage, the ytotal reaction 1/1.O2+2X+2H+ H2O+X2 requires theoretically, only 0.13 volt where X is chlorine, and 1.52 volts where X is uorine.

The saving offered by the present invention in electrical energy required is immediately apparent; the cathode reaction thus produces a portion of the power employed inthe electrolysis of the acid. Additionally, the product of standard electrolysis poses the problem of explosive recombination. In the invention described, as in the prior art, the electrolysis of HF must be done under substantially anhydrous conditions. The presence of Water in the electrolyte results in the formation of oxygen difluoride which represents a substantial explosion hazard. However, the present invention obviates such problems by incorporation of a cation-permeable :barrier through which the hydrogen ions formed in the process are free to pass and combine with the oxygen introduced into the cathode. This not only prevents the formation of gaseous hydrogen, but also effectively bars contamination, by either the water product of the cell or oxygen from the cathode, of the halogen acid which is being processed.

While the presence of water does not pose the hazard with hydrochloric acid as presented with hydrogen uoride, nevertheless it may be desirable to employ an ionpcrmeable membrane, as heretofore described, as barrier 48 to avoid inadvertent introduction of gaseous oxygen into the hydrochloric acid solution, as Well as to prevent undue dilution of the latter by water formed in the process. Of course, substantial amounts of water in the electrolyte will result in the formation of chlorine-oxygen complexes such as perchloric acid which is an undesirable contaminant. Where, however, the primary concern is power saving and contamination is considered an acceptable hazard, it is understood that the invention need not include barrier 48.

The electrical power saving gained in the process o f the present invention with respect to the prior art 1s shown inthe following examples:

Example 1 A 3 N HC1 solution was introduced into a cell similar to that shown in FIGURE l, the cathode being formed of a microporous, sintered silver mat. Upon introduction of only substantially pure nitrogen into the cathode, the observed voltage was 1.5 volts at current densities of 20 ma./cm.2, evolution of chlorine being observed at the anode. The ambient temperature of the cell was 40 C. to 50 C. Upon introduction of yair under pressure into the cathode, and under similar conditions of temperature, evolution of chlorine was observed at the anode at a voltage of 1.0 volt at current densities of 2() Ina/cm?. The energy saving is thus established at 0.5 volt. Ilhe anode employed in both runs was graphite.

Example 2 A mixture of anhydrous HF with approximately 10% KF was introduced into a cell similar to that shown in FIGURE 1. With nitrogen only introduced into the cathode, evolution of -luorine occurred at the anode at a potential of 2.9 volts at 20 rma/cm2; with air introduced into the cathode, at the same current density the potential required to evolve uorine was 1.8 volts.

It is to be understood that, particularly -in the processing of HF, because of the high volatility of the latter, the electrolyte should be cooled to as low a temperature as is commensurate With maintaining ythe electrolyte in a liquid state. Consequently, refrigerant equipment to cool the cell is preferably employed therewith as well as other ancil-lary devices such las condensers or porous NaF llters for stripping HF from the gaseous effluent of the cell, refrigerant equipment to cool the condenser, and valves for metering the llow of fluids and gases, all of which are well known in the art.

While all halogens can be produced lby the electrolytic treatment shofwn herein, HBr and HI can be directly oxidized by air or oxygen, so that this invention is especially important for Ithe oxidation of HC1 and HF.

Since certain changes may be made in the above apparatus and process Without departing from the scope of the invention herein involved, it is intended that all mat- -ter contained in the above description as shown in the accompanying drawing shall be interpreted as illustrative and not in a limiting sense.

What is claimed is:

1. A process for producing a halogen gas selected from the group consisting of chlorine and fluorine comprising the steps of passing a direct electrical current through a cation permeable barrier and a halogen acid, selected from the group consisting of hydrochloric and hydrofluoric acids, located between anode means and microporous cathode means thereby oxidizing the halogen ions at said anode means to form halogen gas and causing hydrogen ions to migrate to said cathode means, introducing an oxidizing gas into said cathode means thus simultaneously causing oxidizing gas depolarization at said porous cathode means thereby preventing the formation of hydrogen `gas and reducing the power consumption required for the electrolytic process.

2. Fllhe process for producing fluorine from hydrofluoric acid compris-ing the steps of passing a direct electrical current through said acid and a cation permeable barrier located between anode means and microporous cathode means to form gaseous tluorine at said anode means, wenting said gaseous fluorine from said anode rneans, introducing lan oxidizing gas into said cathode means thus causing oxidizing gas depolarization thereby preventing the formation of gaseous hydrogen and reducing the power consumption required for the electrolytic process.

3. A pross as defined in claim 2 wherein said oxidiz- 1ng gas 1s arr.

4. A process yas dened in claim 2 wherein said oxidizing gas is oxygen.

5. The process for producing chlorine from hydrochloric `acid comprising the steps of passing a direct electrical current through said acid and cation permeable barrier located between anode means and microporous cathode means to form gaseous chlorine at said anode means, venting said gaseous chlorine from said anode means, introducing `an oxidizing gas into said cathode rneans thus causing oxidizing gas depolarization thereby preventing the formation of gaseous hydrogen :and reducving the power consumption required for the electrolytic process.

6. A process as defined in claim 5 wherein said oxidizing gas includes oxygen.

UNITED STATES PATENTS Heise et al. Feb. 17, 1942 Schumacher Sept. 19, 1944 Juda etal Apr. 28, 1953 Bodamer June 15, 1954 Manecke Jan. 18, 1955 Grubb Nov. 17, 1959 Osborne et `ai Jau. 10, 1961 Butler Jan. 16, 1962 OTHER REFERENCES Heise: Transactions of the Electrochemical Society, 1939, volume 75, pages 147-166. 

1. A PROCESS FOR PRODUCING A HALOGEN GAS SELECTED FROM THE GROUP CONSISTING OF CHLORINE AND FLUORINE COMPRISING THE STEPS OF PASSING A DIRECT ELECTRICAL CURRENT THROUGH A CATION PERMEABLE BARRIER AND A HALOGEN ACID, SELECTED FROM THE GROUP CONSISTING OF HYDROCHLORIC AND HYDROFLUORIC ACIDS, LOCATED BETWEEN ANODE MEANS AND MICROPOROUS CATHODE MEANS THEREBY OXIDIZING THE HALOGEN IONS AT SAID ANODE MEANS TO FORM HALOGEN GAS AND CAUSING HYDROGEN IONS TO MIGRATE TO SAID CATHODE MEANS, INTRODUCING AN OXIDIZING GAS INTO SAID CATHODE MEANS THUS SIMULTANEOUSLY CAUSING OXIDIZING GAS DEPOLARIZATION AT SAID POROUS CATHODE MEANS THEREBY PREVENTING THE FORMATION OF HYDROGEN GAS AND REDUCING THE POWER CONSUMPTION REQUIRED FOR THE ELECTROLYTIC PROCESS. 